SAFETY PRECAUTIONS Operating, Maintenance

Each Series 602 Manually Operated Lever Hoist is built in accordance with the specifications contained herein and at the & Parts Manual

Lever Operated Chain Hoists

time of manufacture complies with our interpretation of applicable sections of *ASME B30.21, *ANSI/ASME HST-3M and the
Occupational Safety and Health Act-1970.

The safety laws for elevators and for dumbwaiters specify construction details that are not incorporated in CM industrial
hoists. We recommend the use of equipment that meets state and national safety codes for such use. Columbus McKinnon
Corporation cannot be responsible for applications other than those for which CM equipment is recommended.
SERIES 602
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED Manually Lever Operated Chain
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND
OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED Hoist
WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR SERIES 602 LEVER HOIST.
Maximum Capacity: 550 Pounds (250 Kg.)
*Copies of the standards may be obtained from ASME Order Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300.

WARNING!
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result in
death or serious injury. To avoid such a potentially
hazardous situation, the operator shall:
CAUTION!
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result in
minor or moderate injury. To avoid such a potentially
hazardous situation, the operator shall:

1. NOT operate a malfunctioning or unusually performing hoist.
2. NOT operate the hoist until you have thoroughly read and
understood this Operating, Maintenance and Parts Manual.
3. NOT operate a hoist which has been modified without the
manufacturer’s approval or certification to be in conformity
with applicable OSHA regulations.
4. NOT lift or pull more than rated load for the hoist.
5. NOT use damaged hoist or hoist that is not working properly.
6. NOT use hoist with twisted, kinked, damaged, or worn load
chain.
7. NOT operate with any lever extension (cheater bar).
8. NOT attempt to “free-chain” the hoist while load is applied.
9. NOT use the hoist to lift, support, or transport people.
10.NOT lift loads over people and make sure all personnel
remain clear of supported load.
11.NOT attempt to lengthen the load chain or repair damaged
load chain.
12.Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
13.NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
14.NOT use load chain as a sling or wrap load chain around load.
15.NOT apply the load to the tip of the hook or to the hook latch.
16.NOT apply load unless load chain is properly seated in the
chain wheel(s) or sprocket(s).
17.NOT apply load if bearing prevents equal loading on all load
supporting chains.
18.NOT operate beyond the limits of the load chain travel.
19.NOT leave load supported by the hoist unattended unless
specific precautions have been taken.
20.NOT allow the chain or hook to be used as an electrical or
welding ground.
21.NOT allow the chain or hook to be touched by a live welding
electrode.
22.NOT remove or obscure the warnings on the hoist.
23.NOT operate a hoist which has not been securely attached
to a suitable support.
24.NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the hook
saddle.
25.NOT lift loads that are not balanced and that the holding
action is not secure, taking up slack carefully.
26.NOT operate a hoist unless all persons are and remain clear
of the supported load.
27.Report malfunctions or unusual performances of a hoist, after
it has been shut down until repaired.
28.NOT operate a hoist on which the safety placards or decals
are missing or illegible.
29.Be familiar with operating controls, procedures and
warnings.
1. Maintain a firm footing or be otherwise secured when
operating the hoist.
2. Check brake function by tensioning the hoist prior to each lift
or pulling function.
3. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
4. Make sure the hook latches are closed and not supporting
any parts of the load.
5. Make sure the load is free to move and will clear all
obstructions.
6. Avoid swinging the load or hook.
7. Avoid lever “fly-back” by keeping a firm grip on the lever until
operating stroke is completed and the lever is at rest.
8. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
9. Use the hoist manufacturer’s recommended parts when
repairing the unit.
10.Lubricate load chain per hoist manufacturer’s
recommendations.
11.NOT use the hoist load limiting or warning device to measure
load (If so equipped).
12.NOT operate except with manual power.
13.NOT permit more than one operator to pull on lever at the
same time. More than one operator is likely to cause hoist
overload.
14.NOT allow your attention to be diverted from operating the
! CAUTION-IMPORTANT
hoist. FORWARD THIS MANUAL TO OPERATOR:
15.NOT allow the hoist to be subjected to sharp contact with If not properly installed, operated and maintained, the use of
other hoists, structures, or objects through misuse. all mechanical equipment presents the possibility of personal
16.NOT adjust or repair the hoist unless qualified to perform injury or property damage. Before hoist use, all persons
such adjustments or repairs. should read this manual thoroughly. For safe, dependable and
economical performance, follow all instructions and recom-
mendations contained herein. It is also important to retain
this manual for current and future use.
Model Number
Serial Number
Purchase Date
®
COLUMBUS McKINNON CORPORATION
INDUSTRIAL PRODUCTS DIVISION
140 JOHN JAMES AUDUBON PARKWAY
AMHERST, NEW YORK 14228-1197

7 02805 Printed in USA MANUAL NO. 602-A

 INSTALLATION
1. Read and understand the safety precautions on page 7 of this manual.
2. Estimate the load that is to be lifted or moved and make sure it does not exceed 550 pounds (250 Kg.).
3. Make sure that the support to which the upper hook is attached is strong enough to hold several times
the weight of the load. Be sure the hoist is solidly held in in the uppermost part of the upper hook, the
latch is closed and the latch does not contact the support.
4. Make sure that the hoist is rigged so that the upper and lower hooks will form a straight line when the
hoist is operated and the frame is free to swivel and will not come in contact with any object.
OPERATION

! WARNING
Failure to use as directed herein may cause injury to you or others and could result in property
damage.
-DO NOT exceed the 550 pound (250 Kg.) capacity of the hoist or 58 pounds (26 Kg.) handle
pull when lifting or pulling.
-DO NOT use the hoist to lift people or loads over people.
-DO NOT use a damaged or malfunctioning hoist.
-DO NOT use if the load chain is twisted, kinked, worn, stretched or damaged.
-DO NOT use unless the hoist’s frame and chain form a straight line between hooks.
-DO NOT use if the hoist’s frame is in contact with any object.
-DO NOT leave a suspended load or hoist under tension unattended.
-DO NOT use an extension on the handle. Operate using hand power only.
-DO NOT apply loads to the tip of the hooks or to the hook latches.
-DO NOT remove warning labels and tags from the hoist.
Before using the Series 602 Lever Hoist, familiarize yourself with main parts (See Fig. 1). Always check
the hoist for proper operation before use and under no circumstance should you attempt to use a
malfunctioning hoist. To reduce the risk of injury, the user must read and understand this manual.

UPPER HOOK

SERIES 602 LEVER HOIST PARTS LIST

Ref. Description Part No. Qty. Ref. Description Part No. Qty.
FRAME No. No.
1 Liftwheel and Shaft 00230161 1 15 Chain guide Roller 00230115 2
DIRECTIONAL 2 Ratchet Hub 00230138 1 16 Stripper 00230116 1
HANDWHEEL LEVER 3 Side Plate Assembly 00230258 2 17 Cover with Nameplate 00230169 1
4 Lever Grip 00230153 1 18 Pawl and Springs 00230259 1
5 Brake Cover 00230124 1 19 Upper Hook Pin 00230131 1
6 Friction Hub 00230113 1 20 Upper Hook Assembly 00230137 1
*7 Brake Disc 00230133 2 21 Lower Hook Assembly 00230137 1
8 Ratchet 00230114 1 22 Handle Assembly 00230164 1
9 Brake Spring 00230130 1 23 Loose End Ring Kit 00230260 1
10 Check Washer 00230117 1 24 Chain Screw and Nut 00230261 1
11 Handwheel 00230155 1 25 Brake Nut and Washer 00230262 1
LOOSE END RING 12 Pawl Stud 00230120 1 26 Cover Nut Kit 00230288 1
13 Side Plate Studs 00230119 2 *27 Latch Kit 00230168 2
HANDLE 14 Spacer 00230121 1 *28 Load Chain (5ft. Lift) 02100004 1
29 Warning Labels, Capacity Label, Nameplate and Drive Screws Kit 00010 1
*These are the only parts CM stocks for repairs. All other parts are available on a special order basis-
contact CM.
LOWER HOOK ALL DIMENSIONS ARE IN CM HOISTS PARTS AND SERVICES ARE AVAILABLE
INCHES (MILLIMETERS) IN THE UNITED STATES AND IN CANADA
BLOCK As a CM Hoist user you are assured of reliable repair and parts services through a network of Master Parts
Depots and Service Centers that are strategically located in the United States and Canada. These facilities
LOWER HOOK have been selected on the basis of their demonstrated ability to handle all parts and repair requirements
promptly and efficiently. To quickly obtain the name of the Master Parts Depot or Service Center located
Figure 1. SERIES 602 LEVER HOIST nearest you call (800) 888-0985. Fax: (716) 689-5644.
CM REPAIR/REPLACEMENT POLICY
CODE: 0210 NET WEIGHT: 5 LBS. (2.3 Kg.)
All Columbus McKinnon (CM®)Hoists are thoroughly inspected and performance tested prior to shipment. If
DC CODE: 60210 SHIPPING WEIGHT: 6 LBS. (2.7 Kg.)
any properly maintained hoist within 1 year of shipment develops a performance problem due to a material
or workmanship defect, as verified by CM, repair or replacement of the unit will be made to the original
MAX. CAPACITY: 550 POUNDS (250 Kg.) MINIMUM DISTANCE purchaser without charge. This repair/replacement policy applies only to hoists installed, maintained and
BETWEEN HOOKS: 9 7/16 IN. (240 mm) operated as outlined in this manual, and specifically excludes normal wear, abuse, improper installation,
improper or inadequate maintenance, hostile environmental effects and unauthorized repairs/modifications.
STANDARD LIFT: 5 FEET (1.5 M) CHAIN SIZE: 4 X 12 mm
CM reserves the right to change materials or design if, in its opinion such changes will improve its product.
PULL ON HANDLE TO LIFT MAX. NUMBER OF 90° HANDLE STROKES Abuse, repair by an unauthorized person, or use of non-CM replacement parts voids the guarantee and
CAPACITY: 58 POUNDS (26 Kg.) TO LIFT LOAD 1 FOOT ( .3 M): 26 could lead to dangerous operation. For full “Terms of Sale”, see Sales Order Acknowledgement.

1 6
FREQUENT AND PERIODIC INSPECTION CHART
ITEM FREQUENCY WHAT TO CHECK INSPECTION ACCEPTANCE FREE CHAINING
EVERY 6 METHOD LEVEL
*DAILY
(FREQUENT) MONTHS In this mode, the load can be pulled through the hoist in either direction by hand for quick attachment
(PERIODIC)
to the load. To set the hoist to free chaining mode:
Labeling and X X Nameplate, capacity label Visual These items must be legible 1. With no load on the hoist, move the directional lever to the center (neutral) position.
Tags warning labels and free and securely fastened to the
chaining tag. hoist. Replace if necessary. 2. *Pull the load chain, in either direction, to its desired length so that the lower hook can be
attached to the load. Note that the chain must feed into the hoist freely. If it does not,
X X General Operation Lift and Lower a 1.Chain must feed into and check for twisted chain. A twisted chain may become damaged by the chain guide rollers
light load. out of the hoist freely.
2. Brake must hold the load or liftwheel and result in chain damage.
when handle is released. *Pull the chain slowly and be careful: HANDLE MAY SPIN.
--- X Overload test. Lift and Lower a 1. Pull on handle should be
688# (312 Kg.) about 73# (33Kg.)
Operation load one foot 2. Brake should operate
(300 mm) smoothly while lowering. OPERATING THE LEVER HOIST
X X Directional Lever Movement Lever must move smoothly.
The Series 602 Lever Hoist can be used in any position as long as it is rigged to pull in a straight line from
X X Free Chaining Movement In free chaining mode, chain hook to hook and the frame is free to swivel on the upper hook.
should feed into and out of
the hoist freely when pulled
by hand.
X X Hook opening and
bowl wear
Measure
opening and
See Figure 4. ! WARNING
bowl wear.

X X Hook latch Operation, 1. Latch must not be If the hoist is not rigged in a straight line hook to hook manner or if the frame is
engagement damaged. not free to swivel on the upper hook, handle pull may break the frame, bend
and damage. 2. Latch must operate upper hook and/or break the chain and cause physical injury or loss of load.
smoothly with sufficient
pressure to engage the
Hook tip of the hook tightly. To Avoid Injury:
Assemblies X X Hook deformation. Visually Hook must not be bent Always rig the hoist in a straight line hook to hook manner and do not allow the
more than 10 degrees from
the plane of the unbent frame to touch the load or any object when in use.
hook.

X X Hook chain screw, Visually There must be no damage,

upper hook pin, hook
collars and hook collars
hardware.
X X Hooks chemical damage,
cracks, gouges
corrosion, excessive wear
or looseness. When operating in limited spaces, use attachments or slings to make sure the frame is free to swivel
on the upper hook and that there are no obstructions that would prevent you from operating the hoist.
Visually There must be no excessive
corrosion, visible cracks or 1. Suspend or attach the hoist from an adequate support (see INSTALLATION).
gouges.

X X Lubrication. Visually Chain should be frequently 2. Following the instruction for FREE CHAINING, take up the slack chain and attach the lower
lubricated using Frisk Bros. hook to load to be lifted or moved. Make sure that the load will be applied to the bowl of the
Lubriplate 10-R, or equal.
lower hook and that it will not be applied to the latch or tip of the hook.
X X Corrosion, Pitting, Gouges. Visually There must be no excessive
Chain corrosion, pitting or gouges
on the chain. 3. To lift or pull load, set the directional lever to (é) LOAD position and slowly pull chain in either
direction by hand to ensure the hoist is out of the free chaining mode. Be careful: HANDLE MAY
X X Wear and deformation. Measure chain See figure 5. SPIN. Then operate the handle up and down to tension the load only enough to check that the
for wear and
stretch. brake is engaged and that the attachments to hooks and load are firmly seated. Then repeatedly
operate the handle up and down to lift or pull the load. DO NOT OVERLOAD! A handle pull of 58
X X Deformation, twists. Visually Chain must be free of twists.
pounds (26 Kg.) results in applying the maximum capacity of 550 pounds (250 Kg.) to the hoist.
---- X Wear and contamination. Measure Replace brake disc if its
Brake thickness and thickness is less than 0.094” 4. To lower or loosen the load, move the directional lever to the (ê) UNLOAD position and operate
Disc visually. (2.4 mm) or if the friction the handle up and down repeatedly.
surfaces are glazed, oily or
contaminated.
---- X Side plate and covers. Visually. Frame and covers should
not be damaged or corroded.
X X Handle Visually. Handle must not be bent or
corroded. Grip should not
! WARNING
be damaged.
Hoist ---- X Stripper Visually. Stripper must not be bent, With no load on the hoist and when the directional lever is in the (é) LOAD or
Head
corroded or worn. (ê) UNLOAD position, pulling sharply on either end of the chain will cause the
X X Hardware Visually. All nuts must not be handle to spin rapidly.
corroded and must be
securely tightened. To Avoid Injury:
---- X Pawl and ratchet. Visually There should be no excessive Never pull sharply on either end of the chain when the directional lever is in the
wear of the ratchet teeth and
the tip of the pawl. The pawl
spring should not be (é) LOAD or (ê) UNLOAD position.
corroded or stretched.
*Daily or before each use.
5 2
 ! WARNING

If directional lever is forced out of engagement with a load applied, load will be
released.
To Avoid Injury:
With a load applied to the hoist, do not force the directional lever into the center
(neutral) position.
CHAIN GUIDE
ROLLER CHAIN GUIDE
LOCKED BRAKE ROLLER

If a hoist under load is suddenly relieved of the load by removing the load from the hoist by some other
means, the brake will remain locked. The brake could also lock if the lower hook block is run tightly against
the frame. To unlock the brake, move the directional lever to the (ê) UNLOAD position and pull sharply on
the handle, or reapply the load and operate the hoist in the normal manner.

MAINTENANCE/INSPECTION STRIPPER
The Series 602 Lever Hoist normally requires very little maintenance, other than the frequent and periodic
inspection listed in the chart on page 5. However, if the hoist is disassembled for inspection, the following
should be observed when reassembling (refer to the exploded view and parts lists for relationship and name LOAD CHAIN
of parts): WELDS AWAY
FROM LIFTWHEEL
1. The pawl must engage the teeth of the ratchet as shown in Figure 2.
2. The check washer must be positioned on the ratchet hub as shown in Figure 2.
LOOSE END RING- LOWER HOOK
3. When installing the chain, it must be fed through the chain guide rollers with the welds away from
POSITION AS BLOCK
the liftwheel, the lower hook must be directly below the upper hook and the loose end ring must
SHOWN
be positioned and oriented at the end of the chain as shown in Figure 3
. 4. A rivet is used to attach the latch to the hook. To remove the latch grind off the head of the rivet.
When installing the latch, only peen over the end of the rivet enough to secure it.

FIGURE 3

PAWL

.149” (3.8mm)
CHECK STOCK DIAMETER
WASHER

0.91” (23.1 mm)

MAXIMUM
THROAT OPENING
1/ “
8

RATCHET
RATCHET PAWL .71” (18mm)
MINIMUM SEAT .496” (12.6mm)
FIGURE 2 MAXIMUM
FIGURE 4 FIGURE 5 PITCH

3 4